Environmentally sustainable packaging and method of making thereof

ABSTRACT

Sustainable packaging and a method of making sustainable packaging including forming the packaging from a predetermined needed material and using the packaging to ship a second part or product, whereby the packaging material is then used to form a first part or product. The packaging includes a plurality of spacer pads arranged in layers and configured to hold the second part or component between the spacer pads. The packaging may also include sheet layers or protective members located between the spacer pads and the parts, the sheet layers may include a volatile corrosion inhibitor. The packaging may also include a sleeve disposed around the spacer pads. A bottom tray located on one end of the sleeve and a lid located on the other end complete the packaging.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to packaging and morespecifically to environmentally sustainable packaging used to ship ortransport articles.

2. Description of Related Art

In today's global manufacturing environment, many parts, components orworkpieces, especially those used in automotive manufacturing, areobtained from worldwide sources. That is, the part or componentmanufacturer may not be located geographically near the assemblyfacility. Thus, the parts or components are packaged and shipped to theassembly facility where there are assembled to form a finished product.An assembly facility can literally receive thousands of parts fromvarious manufacturers located all across the globe, with the parts orcomponents arriving at the assembly facility in various types ofpackaging and/or shipping containers. Ultimately, the assembly facilityis tasked with handling or disposing of the packaging and/or shippingcontainers once the part or component has been removed. Thus, in manycases, the packaging and/or shipping containers are carted off anddiscarded as waste, creating further environmental issues when they endup in a landfill.

Various types of materials are used for packaging or shippingcontainers, one of the primary materials being cardboard. Cardboardpackaging or shipping containers have drawbacks; specifically, dependingupon the particular part or component being shipped they can be a sourceof part contamination. In some cases, cardboard packaging increasesoverall shipping costs since in some instances the part must be removedfrom the cardboard packaging and repacked in a different container priorto reaching its final destination. Cardboard also has poor environmentalsustainability. While cardboard is recyclable, it is not typically usedby the end manufacture or assembly plant and thus must be stored andultimately removed from the assembly facility. In many instances, it issimply discarded after use. Thus, the overall cost to make and recycleor dispose of cardboard packaging impacts the environment and increasesenergy costs.

Wood packaging, such as pallets and boxes, is also used to transportparts or components. Wood packaging is typically expensive to make andmaintain. The wood may be a source of part contamination, maydeteriorate due to adverse weather and may be subject to insectinfestation. Finally, wood packaging or shipping containers also haveissues with recyclability and disposal. As with cardboard, the overallcost to make and recycle or dispose of wood packaging impacts theenvironment and increases energy costs.

Plastic or polymer packaging, such as plastic pallets and boxes are alsoused for shipping parts or components. Plastic packaging may also resultin part contamination. In addition, the initial cost of plasticpackaging typically requires that the packaging be returned to theinitial manufacturer for reuse. Returning the packaging incursadditional costs associated with storing sorting and returning plasticpackaging or shipping materials to the component manufacturer. In manycases, the packaging is part or component specific and thus must bereturned to specific component manufacturers. Accordingly, the cost ofreturning the plastic packaging or shipping materials may outweigh anybenefits obtained over other packaging materials.

Accordingly, it is desirable to have an environmentally sustainablepackaging wherein the material used for the packaging can also berecycled or used by the end user or assembly facility therebyeliminating the need to discard or return the packaging or shippingmaterials to the component manufacturer.

SUMMARY OF THE INVENTION

Accordingly, the present invention is sustainable packaging and methodof designing such packaging. In general, the sustainable packaging isdesigned by taking into account or determining a need for a particularraw material used to manufacture a first product. The method includesdetermining packaging requirements for a second product. Accordingly,the packaging for the second product is designed such that it includesor is formed of the raw material needed for the first product. Thus,upon removal of the second product from the packaging, at least aportion of the packaging can be used to manufacture the first product.Designing and using sustainable packaging according to the presentinvention saves on overall costs, reduces energy consumption andconserves resources.

The present invention also includes sustainable packaging fortransporting a part or component wherein at least a portion of thepackaging is intended for use to manufacture a predetermined article orproduct. Accordingly, the packaging supplies the recipient of thepackaging with a raw material with which to manufacture thepredetermined article or product. The packaging includes a top andbottom layer formed of a material used to form the predetermined articleor product. The top and bottom layer are configured to hold thetransported part or component. First and second sheet layers positionedor sandwiched between the top layer and the part and between the bottomlayer and the part help protect the transported part or component duringshipment. A predetermined amount of layers are stacked upon one anotherand sandwiched between a bottom tray and the lid. A sleeve extendingbetween the bottom tray and the related surrounds the layers and formsan outer wall to complete the packaging.

One advantage of the present invention is that the packaging is designedwith a predetermined end use; specifically, providing raw material usedto manufacture a part or component. Thus, the packaging has a twofoldfunction; it transports a part or component after which it is formedinto a predetermined article or product. Accordingly, the packagingeliminates material from the waste stream and adds value to thepackaging.

These and other features and advantages of the present invention willbecome apparent from the detailed description provided hereinafter. Itshould be understood that the detailed description and specificexamples, while indicating the preferred embodiment of the invention,are intended for purposes of illustration only and are not intended tolimit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram illustrating the overall method of oneembodiment of the present invention.

FIG. 2 is a block diagram illustrating a plurality of steps forreviewing current packaging according to the present invention.

FIG. 3 is a block diagram illustrating a plurality of steps fordesigning packaging according to the present invention.

FIG. 4 is an exploded perspective view of sustainable packagingaccording to the present invention.

FIG. 5 is a cross-sectional view of the sustainable packagingillustrated in FIG. 4 shown in an assembled condition.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings and more particularly to FIG. 1 thereof, ablock diagram of a method 10 for developing sustainable packaging basedon a predetermined material selection according to one embodiment of thepresent invention is illustrated. In this embodiment, the method 10 isused to develop packaging, seen generally at 50 in FIG. 4, forpowertrain components 14 wherein at least a portion of the packaging 50is reused to manufacture a second part or product.

In operation, the method 10 begins with block 16, wherein the need formaterials to manufacture a first part or product, such as a splashshield for a motor vehicle is assessed. Specifically, the methodcontemplates beginning with a particular part or component manufacturedfrom a predetermined material. Once the material needs are determinedfor the first part or product, as illustrated in block 18, the methodincludes reviewing packaging currently used for transporting a secondpart or product, illustrated in the present embodiment as a powertraincomponent. The review may include determining packaging requirements forthe second part or product such as ergonomic requirements, corrosionrequirements, contamination prevention requirements and part support.

Block 20 illustrates that the method includes determining whether thepredetermined material will satisfy the packaging needs orspecifications determined in the previous step, block 18. Once it isdetermined that the predetermined material will meet the packaging needsof the second part or product, as illustrated in block 22, the next stepis to design packaging for the second part or product. The packaging isdesigned such that at least a part of the packaging will be constructedfrom the predetermined material used to manufacture the first part orproduct.

Upon completing the design, the proposed packaging then, as illustratedin block 24, undergoes a variety of tests. For example, a finite elementanalysis is performed on the design concept to establish the viabilityof the proposed packaging. Continued testing includes manufacturing aprototype and subjecting it to a shake test and a load test. Uponsuccessful completion of the testing phase, as illustrated in block 26,packaging is manufactured and used to transport the second part orproduct from a manufacturing facility to a final destination, often anassembly facility. As illustrated in block 28, removal of the secondpart or product from the packaging enables use of that portion of thepackaging formed from the predetermined material in a process tomanufacture the first product.

Accordingly, the overall method of the present invention is comprised ofthree interrelated parts: first, determining an end use or need for aparticular or predetermined material used to manufacture a firstproduct, typically a polymer material; second, defining packagingcriteria for transporting a second product; and third designingpackaging for the second product using the predetermined material.

Turning now to FIG. 2, block 18 is shown in detail and includes blocks30-36. Block 30 includes the step of evaluating contamination issuesassociated with the current packaging. For example, with cardboardpackaging, cardboard fibers may contaminate the part. Additionally, openrack containers also allow for part contamination. Block 32 includes thestep of evaluating environmental waste; specifically, cardboardcontainers and wood pallets are typically treated as waste material thatmust be disposed once the second part or product reaches its enddestination.

Block 34 includes the step of evaluating non-value added steps. It maybe necessary to remove the part or product from the original packagingand repack it prior to the part or product reaching its finaldestination. For example, when cardboard is used as packaging, cardboardfibers can create contamination issues. Accordingly, prior totransporting the part or product to its final destination to preventcontamination at the final destination, the part or product is removedfrom the cardboard container and repacked in a different container.Finally, block 36 includes the step of evaluating the quality issuesincluding part-to-part contact, corrosion issues and other packagingconcerns that may result in damage to the part or product.

Turning now to FIG. 3, block 22 is shown in detail and includes blocks38-46. Block 38 includes evaluating international packagingrequirements, including standards for sea-containers. Block 40 includesevaluating the requirements for intermodal shipping includingtransferring the packaging through various types of shipping includingocean, rail and truck. Block 42 includes evaluating the corrosionprotection needs of the part or product. Block 44 includes evaluatingany potential contamination issues associated with the part or product.Block 46 includes evaluating any ergonomic requirements, includingloading and unloading the second part or product from the packaging.

It should be understood that the above-identified steps are notinclusive of all steps taken to create packaging according to thepresent invention. Nor must every step be taken in order to createsustainable packaging according to the present invention. One aspect ofthe present invention is a method for use in designing packaging from apredetermined end use material, whereby at least a portion of thepackaging is formed of the predetermined end use material. Accordingly,at least a portion of the packaging is recycled and formed into a firstproduct made from the end use material after removal of the second partor product from the packaging.

FIGS. 4-5 illustrate packaging 50 formed in accordance with the methodof the present invention. As illustrated herein, the packaging is usedfor transporting or shipping a powertrain component 14. The packaging 50includes a bottom spacer pad 52 and a top spacer pad 54. The bottom andtop spacer pads 52, 54 may include a shaped receptacle or cutout 56 thatreceives the part, in the present embodiment the powertrain component14. The bottom and top spacer pads 52, 54 may be molded with the shapedreceptacle or cutout 56. In addition, each spacer pad 52, 54 may be madeup of any plurality of individual layers, wherein one or more of thelayers is die cut with the shaped receptacle or cutout 56 prior toassembling the individual layers to form the spacer pads 52, 54.

The packaging further includes protection sheets or layers 58 dispersedbetween the powertrain components 14 and the bottom and top spacer pads52, 54. Depending upon the material used for the bottom and top spacerpads 52, 54 the sheets 58 perform several functions. Initially, thesheets 58 prevent direct contact between the bottom and top spacer pads52, 54 and the powertrain components 14 to eliminate any wear betweenthe two. Specifically, if the powertrain components 14 rub on the bottomand top spacer pads 52, 54 a small amount of material from the bottomand top spacer pads 52, 54 may be removed and cause part contamination.

In addition, the sheets 58 may include a volatile corrosion inhibitorimpregnated therein. Accordingly, the volatile corrosion inhibitor inthe sheets 58 will vaporize and attach to the powertrain components 14and form a protection layer that prevents humidity, salt, dirt and othercontaminants from depositing on and causing corrosion of the powertraincomponents 14.

The packaging 50 further includes a bottom tray 60 having legs 62arranged in a pallet configuration. A sleeve 64 surrounds the bottom andtop spacer pads 52, 54 and forms an outer wall of the packaging 50. Alid 66 fits over and on top of the sleeve 64 to complete the packaging.In accordance with the present invention, the bottom and top spacer pads52, 54, bottom tray 60, sleeve 64 and lid 66 are all made from apredetermined polymer, such as polypropylene, suitable for use as a rawmaterial to manufacture a preselected part or product.

The packaging is used as follows, the sleeve 64 is placed into thebottom tray 60 after which a bottom spacer pad 52 is placed in the tray60. One of the protective sheets 58 is placed on the bottom spacer pad52. A part, illustrated herein a powertrain component 14, is placed ontop of protective sheet 58 such that it sits in one of the shapedreceptacle or cutout areas 56 of the bottom spacer pad 52. A secondprotective sheet 58 is then placed on top of the powertrain component 14layer after which a top spacer pad 54 is placed on the top protectivesheet 58 and over the powertrain component 14 layer. The process iscontinued in a layer-by-layer manner until reaching the top of thesleeve 64 at which time the lid 66 is placed on the sleeve 64. Theentire packaging 50 may be secured with bands or straps extending aroundthe bottom tray 60, sleeve 64 and lid 66.

One advantage of the present packaging 50 is that the spacer pads 52, 54forming each layer operate to separate the parts or products, shownherein as powertrain components 14. Since the powertrain components 14are stacked on top of each other, they bear their own weight and supportone another rather than the packaging being designed to support theweight of the powertrain components 14. Further, while shown with topand bottom spacer pads 54, 52, depending upon the part or product beingtransported, the packaging 50 may use a single pad between each layer ofparts. For example, if the part or product has a relatively simpleconfiguration, a single layer between the parts may suffice. Inaddition, the shaped receptacle or cutout 56 may be located on bothsides of a single spacer pad.

In accordance with the present invention, prior to designing thepackaging for the powertrain components 14, it was determined thatpolypropylene was a needed material to manufacture a first product, forexample a vehicle splash shield. Accordingly, knowing that there is apredetermined need for polypropylene material to manufacture a firstproduct, current packaging designs for transporting other products;i.e., a second part or product, are reviewed to determine ifpolypropylene can be used for packaging the second part or product.

In the present example, currently cardboard containers are used totransport the powertrain components 14. Cardboard containers contributeto part contamination. Cardboard fibers can cause serious contaminationproblems with powertrain components. To prevent contamination thecomponents are sometimes inserted in a plastic bag prior to placement inthe cardboard container. In addition, cardboard containers require arepack step as powertrain assembly plants typically restrict the use ofcardboard shipping materials to prevent part contamination. Accordingly,this increases costs of using cardboard containers to ship powertraincomponents. By using polypropylene as the base material for thepackaging 50, the materials may be reused thereby eliminating costlywaste and repack costs. Accordingly, once the powertrain components 14are removed from the packaging 50, the polypropylene components,specifically the bottom and top spacer pads 52, 54, bottom tray 60,sleeve 64 and lid 66 are subjected to a regrind process to transformthem into raw material used to form the first part or product, disclosedherein as a vehicle splash shield.

Accordingly, using packaging made from a predetermined material having aknown end use to transport parts or products has dual savings; first, iteliminates problems associated with non-value added repackaging andsecond, it supplies raw material for manufacturing a second part orproduct. Thus, the present invention provides sustainable packagingdesigned to transport a second part or product. Once the second productis delivered to its end destination, the packaging is then recycled as araw material to form a first part or product.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

1. A method of making sustainable packaging comprising the steps of:determining a need for a raw material for making a first product;determining shipping and packaging requirements for a second product anddesigning packaging for said second product from the raw material usedfor making said first product.
 2. A method of making sustainablepackaging as set forth in claim 1 including the step of analyzingcurrent packaging for said second product including identifying problemswith current packaging.
 3. A method of making sustainable packaging asset forth in claim 1 including the step of developing a problemstatement to evaluate current issues with current packaging, said stepincluding addressing issues related to contamination, environmentalwaste, non-value added steps and part quality.
 4. A method of makingsustainable packaging as set forth in claim 1 including the step ofevaluating packaging design criteria for the second product.
 5. Inmethod of making sustainable packaging as set forth in claim 1 includingthe step of testing the packaging.
 6. A method of making sustainablepackaging as set forth in claim 5 wherein the step of testing thepackaging includes the step of performing a finite element analysis onthe proposed package design.
 7. A method of making sustainable packagingas set forth in claim 1 including the step of preparing a prototype andtesting the prototype.
 8. A method of making sustainable packaging asset forth in claim 1 including the step of identifying acceptedstandards and criteria for assessing performance, reliability andmanufacturing capability of the packaging; and verifying that thepackaging meets accepted standards and criteria.
 9. A method of makingsustainable packaging as set forth in claim 1 including using a polymermaterial as a raw material.
 10. A method of making sustainable packagingas set forth in claim 1 wherein the step of the designing packaging forthe second product includes providing a bottom member; a sleeve member,a lid and a plurality of bottom and top spacer pads sized to fit withinthe sleeve and configured for placement on opposite sides of the secondproduct to form a layer.
 11. A method of making sustainable packaging asset forth in claim 1 including using a protective sheet between thesecond product and the spacer pad.
 12. A method of making sustainablepackaging as set forth in claim 11 including using a protective sheethaving a volatile corrosion inhibitor impregnated in the protectivesheet.
 13. A method of forming a part or product from packaging materialcomprising: determining a need for materials to manufacture a firstproduct; reviewing design criteria for packaging used to transport asecond product; designing packaging for use with the second product, thepackaging constructed, at least in part, from the material used tomanufacture the first product; transporting the second product in thepackaging ; and removing the second product from the packaging and usingthe material of the packaging to form the first product.
 14. A method ofobtaining material as set forth in claim 13 wherein the step ofdetermining need for materials to manufacture a first product includesassessing current material needs.
 15. The method of obtaining materialas set forth in claim 13 wherein the step of reviewing packaging fortransporting a second product includes evaluating at least in part thefollowing concerns: contamination issues, environmental waste, non-valueadded steps and quality issues associated with transporting the secondproduct.
 16. The method of obtaining material as set forth in claim 13wherein the step of designing the packaging for use with the secondproduct includes evaluating the proposed packaging at least in partbased on several requirements, including international packaging,intermodal packaging, corrosion protection, contamination protection andergonomic issues.
 17. The method of obtaining material as set forth inclaim 13 wherein the step of reviewing the packaging includes analyzingenvironmental costs including end-user costs relating to transportationand disposal; and analyzing fabrication costs as a component of theoverall packaging cost.
 18. The method of obtaining material as setforth in claim 13 including the step of using a polymer material to formthe packaging ; and regrinding and reusing the polymer material to formthe first product once a second product is removed from the packaging.19. Packaging for transporting a second product wherein at least aportion of the material forming the packaging is used to form a firstproduct, said packaging comprising: at least one layer formed of aplurality of members, said layer including first and second spacer pads,at least one of said spacer pads configured to fit the second product,said second product located between said spacer pads, sheet memberslocated between said first and second spacer pads and the secondproduct; and a sleeve, said sleeve surrounding said layer.
 20. Packagingfor transporting a second product as set forth in claim 19 wherein saidprotective sheets include a volatile corrosion inhibitor.
 21. Packagingfor transporting a second product as set forth in claim 19 including abottom tray; and a lid, wherein said lid is located on one end of saidsleeve and said bottom tray is located on said opposite end of saidsleeve.
 22. Packaging for transporting a second product as set forth inclaim 21 wherein said bottom tray includes a plurality of legs. 23.Packaging for transporting a second product as set forth in claim 19including a bottom tray and a lid, said spacer pads, bottom tray,sleeve, and lid made from a polypropylene material used to manufacturethe first product.
 24. Packaging for transporting a second product asset forth in claim 19 including a plurality of layers located withinsaid sleeve, said protective sheets located in said layers including avolatile corrosion inhibitor; a lid located on one end of said sleeve;and a bottom tray having a plurality of legs located on an opposite endof said sleeve.
 25. Packaging for transporting a second product as setforth in claim 24 including said first and second spacer pads configuredto fit the first article.